Baseball bat with replaceable barrel

ABSTRACT

A baseball or softball bat configured to allow the removal and replacement of the barrel section of the bat if the barrel is damaged or simply for enabling selection of a barrel having particular performance characteristics. Alternatively, the barrel may be selectively changed to meet certain regulation requirements. In one aspect, one or more components of the ball bat can be provided as a kit. In another aspect, the ball bat can be made by forming and assembling the components simply and inexpensively. Exemplary embodiments include a center tube or handle, a transition, and a barrel some or all of which can be separably combined during assembly.

BACKGROUND OF THE INVENTION

[0001] 1. Technical Field

[0002] This invention generally relates to baseball and softball batsand, more particularly, to reconfigurable bats that allow for thereplacement of the barrel should a different level of performance bedesired or should the barrel become damaged.

[0003] 2. Background Art

[0004] The disclosures and inventions of the past are deficient inteaching the use of a bat with a barrel section that may be removed fromthe bat and replaced with a new section when a change in the performancecharacteristics of the bat is required or when the barrel sectionbecomes damaged. Rather, the approaches of the past address the issuesof performance and durability by trading-off one against the other in anattempt to achieve a balance which the user might appreciate.

[0005] On the contrary, the designers of baseball and softball bats havehad as a primary object, a bat that can hit a ball long distances.Designers have as a secondary object a bat which is durable and cansurvive repeated impacts with the ball. It is difficult to accomplishone of these objectives without compromising the other.

[0006] The characteristics of a bat are very largely determined by thetypes of materials and the geometry of the components including athickness of the barrel section of the bat. Depending upon theperformance and/or durability desired, the bat may be very durable oreasily susceptible to damage during play. Likewise, its performance,measured by the batted ball speed, may be high or low. Most highperformance bats manufactured today are hollow. They rely upon thedeformation of the barrel wall, principally in the hoop mode, to providea so-called “trampoline effect” which leads to higher batted ballspeeds. Bats of this construction can be as much as 50% more efficientthan solid wood bats. That is, the batted ball speed can be as much as50% higher for hollow bats than for wooden bats. Because such highperformance gives an advantage to the batter, most players prefer to usea bat with as high a performance rating as possible. Higher batted ballspeeds, however, put the pitcher and other infielders at some risk ofbeing struck by a ball traveling so rapidly that they have insufficienttime to react. To protect players in the infield, bat performance isgenerally regulated. To be competitive, bats must perform at or nearthese regulated limits. However, even to achieve these regulated limits,barrel walls must generally be thinned to the point that durabilitybecomes an important issue. It is common, among the highest performingpopulation of bats, especially in the hands of good athletes, for thesebats to be damaged within 50-500 impacts. This damage renders the batsof the past unsuitable for further use.

[0007] The first bats ever produced were made from solid wood and wereof one piece construction. This design endured without significantchange for about ¾ of a century until hollow aluminum bats wereintroduced. These aluminum bats and subsequent composite bats havefollowed the original wooden bats in form except for their hollowconstruction. Designers have continued to struggle with the tradeoffbetween performance and durability. Their solutions have been deficientin many regards.

[0008] Numerous solutions have been proposed for improving durability,all with varying degrees of success. In each case, efforts to improvethe durability of the bat generally result in a reduction inperformance. The liveliness of the bat, principally resulting from theso-called “trampoline effect” is closely tied to the stiffness of thebarrel section of the bat. To some degree, reducing stiffness increasestrampoline effect and vice-versa. Increasing thickness of the barrelwall quickly increases the bending stiffness of the wall, allowing thewall to deform less, and reducing the trampoline effect as a result.Another shortcoming resulting from these approaches is an increase inthe bat's weight and its polar moment of inertia, both making the batmore difficult to swing rapidly and decreasing the batter's ability tohit the ball well.

DISCLOSURE OF THE INVENTION

[0009] The present invention relates to a baseball or softball bat thatis provided with a means to quickly and easily remove and replace thebarrel section of the bat by one of a variety of different barrelsections configured for different levels of performance and durabilitydepending upon the batter's level of play and the rules of the game inwhich the bat is being used. This aspect of the invention also allowsreplacement of the barrel section whenever it has become damaged,whether through contact with the ball as occurs in the normal course ofplay, or otherwise.

[0010] The invention includes the idea of accepting limited durabilityin exchange for higher performance without investing in a bat that isprone to irreparable failure. The practical application of this ideaenables an end user to easily and affordably choose between more or lessperformance and more or less durability as the situation demands. Incase of failure of a particular barrel section, the barrel section cansimply be replaced without the loss of the complete bat. Specifically,the invention enables a batter to modify the performance level of a bat,either to a higher or a lower level, based upon his or her ability leveland based upon the rules of the game as imposed by local or nationalrules making bodies. In fact, a bat can be modified to enable its use inboth softball and baseball.

[0011] Furthermore, a bat of the present invention can be modified forseveral levels of play. For example, a first highest level may bedefined in terms of the intended function of hitting the ball as far aspossible, or a home run level. A second intermediate level ofperformance may be defined by its intended function of enabling a hitterto make a base hit. A barrel having characteristics for thisintermediate level of performance may be useful for cases in which themaximum number of home runs has been achieved in a given game, and areduced performance is desired to avoid additional home runs. A thirdlower level of performance for a practice or swing bat has even lowerperformance, but is much more durable. A fourth level of performance isspecifically configured to be more durable in cold weather conditions.Thus, there is disclosed herein means for quickly and easily replacing abarrel section of a softball or baseball bat to selectively modify aperformance level of the bat.

[0012] The invention also includes enabling these modifications to bemade quickly, by the bat owner, without need to return the bat to amanufacturer, dealer, or other third party. Related to this feature, thecomponents can be of low complexity that can be easily manufactured inmass or lots so that the components can be kept in stock to be readilyavailable. Alternatively, extras can be kept by the user. Thus,replacement of the components including the barrel section to return abat to a state of playability is easy and inexpensive.

[0013] An example of a bat that implements the invention accordingly ina simple form is a reconfigurable ball bat having a center tube with afirst diameter and a first length extending between a proximal end and adistal end of the center tube. The bat further includes a transitionpiece mounted on the center tube at a position spaced from the proximalend of the center tube. The minimum diameter of the transition piecebearing surface is greater than or equal to approximately twice thefirst diameter. In one aspect, the transition piece has a bearingsurface with a minimum diameter in the range from 2 to 3½ times thefirst diameter. The bat also has a barrel with a proximal end includinga proximal bearing surface. The proximal bearing surface has a minimumdiameter greater than or equal to approximately twice the firstdiameter. In one aspect, the proximal bearing surface has a minimumdiameter in the range from 2 to 3½ times the first diameter. In theassembled state, the proximal bearing surface of the barrel is solely incontact with the bearing surface of the transition piece so thatstructural contact only occurs at a diameter equal to or greater thanapproximately twice the first diameter. In one aspect, the structuralcontact between the barrel and the transition only occurs at a diameterin the range from 2 to 3½ times the first diameter.

[0014] In one aspect of the invention, structural components that holdthe barrel on the transition piece can include the center tube beingconnected to the end cap. One way this can be achieved is by connectingan end plug to a distal end of the center tube. An end cap is alsoprovided and abutted with a distal end of the barrel. An assembly screwengages in the end plug and holds the end cap on the distal end of thebarrel. In this way, the end cap provides a coupler at a distal end ofthe barrel. Thus, the coupler removably mounts the barrel on thetransition piece.

[0015] In another aspect of the invention, the coupler is one of aplurality of couplers. Some of these couplers can be interchanged on agiven bat. The couplers can have minimum diameters in the range fromapproximately 2 to approximately 3½ times the diameter of the centertube so that a coupler can be selected to accommodate a selected barrel.This aspect of the invention highlights the reconfigurability of thebats of the invention. This reconfigurability lends itself to anotheraspect of the invention, which is that one or more component of a batcan be packaged or provided as a kit.

[0016] While the kit may include as few as one component, typically thekit would include more than one component including assemblyinstructions. For first time purchases, the kit would normally include acomplete ball bat. In this case, the reconfigurable ball bat kit wouldinclude a center tube, at least one transition piece, and at least onebarrel. This kit may have the barrel selectively connectable andseparable from the center tube. The kit may further include a pluralityof barrels that are selectively supported on the center tube by thetransition piece.

[0017] Another aspect of the invention is a method of using thereconfigurable ball bat. This method entails selecting a component toreplace an existing component on the reconfigurable bat. As such, theinvention more specifically includes selecting a replacement barrel toreplace an existing barrel. The replacement barrel is supported on thecenter tube by at least one transition. Added advantages are furtherprovided when the replacement barrel is selected from among a pluralityof barrels.

[0018] In another aspect, the invention includes a method of making aball bat. This method includes forming a center tube to have a firstinner diameter and a first outer diameter. Making the ball bat alsoincludes forming a transition piece with an outer surface including abarrel abutting bearing surface and an opening having an inner surface.A dimension of the inner surface matingly receives the first outerdiameter of the center tube. Another step in the method of making isforming a barrel having a second outer diameter and a second innerdiameter. The second inner diameter is made to match the barrel abuttingbearing surface on the outer surface of the transition piece so that thebarrel fits on the barrel abutting bearing surface. The variouscomponents of the ball bat are assembled by connecting the transitionpiece to the center tube and the barrel to the barrel abutting bearingsurface of the transition piece.

[0019] In one aspect of the method of making, the step of connecting thebarrel to the transition piece is facilitated by providing an end capfor the ball bat. The end cap is connected to a distal end of thebarrel. The end cap supports the barrel on the transition by also beingconnected to the center tube. To this end, an end plug is formed andconnected to a distal end of the center tube. An assembly screw or nutis provided and used for connecting the end cap to the barrel byengaging the screw or nut with the end plug. Alternatively stated,connecting the barrel to the transition piece can be accomplished byabutting a proximal end of the barrel with the barrel abutting bearingsurface of the transition piece, abutting the end cap with the distalend of the barrel, and clamping the barrel between the transition pieceand the end cap. The clamping action is effected by engaging theassembly screw or nut with the end plug and turning the assembly screwor nut.

[0020] It is to be understood that in all aspects of the invention setforth above, the barrel is removably mounted to the transition piece bystructure that can be manipulated by hand or with a tool so that thebarrel can be removed and replaced quickly and easily. In anotheraspect, the invention has structure on one or more of the center tube,transition piece, and the barrel enabling simple manipulation so thatthe kit can be assembled and disassembled quickly and easily in a dugoutor on the field for example.

[0021] In another aspect the invention includes a reconfigurable ballbat in a range of standard sizes for baseball and softball. This ballbat includes a handle portion, a barrel section removably connected tothe handle portion, and a butt end supported on the barrel. This bat,assembled with a knob supported on the handle portion, has a lengthwithin the range of standard sizes for ball bats. Furthermore, the batmeets all the standards for ball bats established by at least onerecognized official regulating organization such as the NCAA or ASA, forexample. These standards commonly include a weight requirement in ouncesequal to the length of the bat in inches minus at least three. In thisaspect, the reconfigurable ball bat has all the couplers and structuralelements to securely hold the various components together. Yet thereconfigurable ball bat can weigh less than or equal to 30 ounces, whichis approximately the practical upper weight limit for competitivestandard bats. In some configurations the bat weighs less than or equalto 28 or 26 ounces respectively. In still further configurations, theball bat weighs in a range from 22 to 24 ounces. These advantageouscharacteristics are provided in part by incorporating light weightmaterials in the bats of the present invention as will be furtherdescribed below.

[0022] To provide reassurance that the bats of the present inventionmeet and will continue to meet the established regulations of a givenorganization, the bats of the present invention include at least one ofthe handle portion, a barrel section, and a butt end that is removablyconnected to the rest of the bat so that the bat can be easily andquickly taken apart for inspection and put back together on the field.

[0023] Furthermore, the invention in any of its forms can include atamper resistant element for connection to the center tube or to thebarrel section. The tamper resistant element inhibits tampering with thecenter tube or barrel without obvious modification to the tamperresistant element. Thus, if a user attempts to modify the bat by addingor removing material from the center tube or barrel section, anoticeable modification of the tamper resistant element will occur. Anofficial may take the bat apart and inspect it to detect any suchtampering.

[0024] It is contemplated that the tamper resistant element may be anenclosing seal covering otherwise open ends of a barrel, for example.Alternatively, the tamper resistant element may be configured as a tubeor sleeve surrounding a center tube, or covering an inner surface of abarrel section. Typically, this tamper resistant element will beflexible, and generally will not contribute substantially to thestructural strength of the bat. However, it is contemplated that thetamper resistant element may provide an advantageous function ofselectively adding a predetermined amount of weight at a predeterminedlocation. For example, a tubular sleeve of a predetermined thickness andweight could extend along the center tube as a protective layer and aweight adding ballast.

[0025] The foregoing and other features and advantages of the presentinvention will be apparent from the following more detailed descriptionof the particular embodiments of the invention, as illustrated in theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0026]FIG. 1 is a perspective view of a bat in accordance with a firstembodiment of the invention comprising an integral handle and transitionsection and an attached barrel section;

[0027]FIG. 2 is an exploded perspective view of the bat of FIG. 1;

[0028]FIG. 3A is an exploded perspective view of a region 3A of FIG. 2showing a pair of fittings used to connect the bat handle and barrel ofFIGS. 1 and 2;

[0029]FIG. 3B is a sectional view taken along lines 3B-3B of FIG. 3A;

[0030]FIG. 3C is a sectional view taken along lines 3C-3C of FIG. 3A;

[0031]FIG. 4 is a perspective view of a bat in accordance with a secondembodiment of the invention comprising a central tube or handle, amounted transition section, and an attached barrel section;

[0032]FIG. 5 is an exploded perspective view of the bat of FIG. 4;

[0033]FIG. 6A is an more detailed exploded perspective view of a set offittings used to connect the barrel and the handle of the bat of FIGS. 4and 5;

[0034]FIG. 6B is a sectional side view of the variation of the fittingsof FIG. 6A in a partially assembled state;

[0035]FIG. 7A is a perspective view of a bat in accordance with a thirdembodiment of the invention comprising a long central tube, an attachedtransition section and a barrel clamped between the transition sectionand a hollow end cap;

[0036]FIG. 7B is an exploded perspective view of the bat of FIG. 7A;

[0037]FIG. 7C is a sectional side view of a transition piece and barrelinterface of the bat of FIG. 7A;

[0038]FIG. 7D is an exploded perspective view of a threaded plug fittingand the central tube used in the bat of FIGS. 7A and 7B;

[0039]FIG. 7E is an exploded perspective view of a hollow end cap, anut, and the barrel used in the bat of FIGS. 7A and 7B;

[0040]FIG. 7F is a sectional side view of a variation of the end plug,end cap, and nut in accordance with the embodiment of FIGS. 7A and 7B;

[0041]FIG. 8A is an exploded perspective view of a bat in accordancewith a fourth embodiment of the invention; and

[0042]FIG. 8B is a sectional side view of the bat of FIG. 8A showing theconfigurations of an end plug, an end cap, and a screw in an assembledstate.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

[0043] As discussed above, embodiments of the present invention relateto a reconfigurable bat. Throughout the remainder of the description,the bats of each of the embodiments are described with the end of thebat that is normally held by the user during play defined as theproximal end, and the end closer to where the ball normally strikes thebat defined as the distal end.

[0044]FIG. 1 is a perspective view of a first embodiment of a bat 5 witha removable barrel 11 consisting of an integral handle and transition 15and a barrel 11 joined together with a pair of threaded fittings (21 and22) as shown in the exploded view of FIG. 2. The bat 5 is closed on aproximal end with a knob 16 and on the distal end with a solid end cap18. The bat 5 is a hollow bat that behaves similarly to existingaluminum and composite bats with the exception that the barrel 11 may beseparated from the integral handle and transition 15 simply byunscrewing one from the other. The knob 16 is permanently attached tothe integral handle and transition 15. This can be achieved either bywelding or gluing. Alternatively, the knob 16 is integrally molded withthe handle 14 during manufacture. Similarly, the solid end cap 18, canbe permanently attached to the barrel 11.

[0045] The barrel 11 is comprised of a hollow cylinder fabricated frommetal such as aluminum or fiber reinforced composites such as graphitefiber, fiberglass or aramid fibers in a polymer matrix such as epoxy,thermoset, or thermoplastic resins. It may also be fabricated from woodif a lower performance bat is desired. The barrel 11 ranges in lengthfrom about 7 inches to about 14 inches and ranges in thickness fromabout {fraction (1/20)} inch to about ¼ inch, depending on the materialof construction. The diameter of the barrel 11 may be of any size, buttypically will range in size from about 2¼ inches to about 2¾ inches.The ends of the barrel are normal to a central axis 25. On one end ofthe barrel 11, an aluminum threaded sleeve 21 is attached via adhesivebonding and/or rivets to firmly secure the sleeve 21 to the barrel 11.The sleeve 21 is preferably a threaded female fitting. To the other endof the barrel 11, a solid end cap 18 is attached via adhesive bonding tofirmly secure these two pieces together.

[0046] The integral handle and transition 15 is a hollow section madefrom aluminum or fiber reinforced composites such as graphite fiber,fiberglass or aramid fibers in a polymer matrix such as epoxy,thermoset, or thermoplastic resins. To a distal end of the integralhandle and transition 15, as shown in FIG. 2, an aluminum male threadedflange fitting 22 is attached via welding or adhesive bonding and/orrivets to firmly secure the flange fitting 22 to the handle andtransition piece 15. To the opposite end of the integral handle andtransition 15, a knob 16 is mechanically attached via welding or apinned and adhesive joint. Alternatively, the knob 16 can be co-moldedwith the handle and transition 15 if it is made from plastics orcomposites. In any case, the barrel 11, the sleeve 21, and the end cap18 form a barrel assembly of a first permanently joined group of parts.Similarly, the handle and transition 15, the knob 16, and the flangefitting 22 form an integral handle and transition assembly of a secondpermanently joined group of parts.

[0047] The resulting two-piece bat 5 functions similarly to existingone-piece bats until such time as the barrel 11 is damaged or the batterchooses to replace it by changing the barrel 11 to a barrel of differingperformance characteristics better suited to the current game. At thattime, a barrel assembly is unscrewed from an integral handle andtransition assembly and a new barrel assembly is screwed into place.

[0048]FIG. 3A is a more detailed exploded perspective view of a region3A of FIG. 2. The fittings 21, 22 and respective portions of the bat 5to which the fittings 21, 22 are connected are shown. In this figure thegeometry of the threaded fittings 21, 22 is better shown. These drawingsdepict representative configurations for both parts and are not meant tobe restrictive so long as the function of joining the two principlesections of the bat is maintained. Also shown more clearly are thesurfaces which may be bonded or otherwise attached to the insidediameters of the integral handle and transition 15 and the barrel 11.

[0049]FIGS. 3B and 3C are sectional views taken along lines 3B-3B and3C-3C of FIG. 3A respectively. The sleeve fitting 21 has female threads27 and a radially protruding rib 29 extending outwardly from a sleeveportion of the fitting 21 as shown in FIG. 3B. The male threaded fitting22 has male threads 31 and a radially extending rib 33 extendingoutwardly from a sleeve portion of the fitting 22. The radiallyextending ribs 29, 33 can provide a snap lock attachment to the handleand transition 15 and to the barrel section 11 to compliment rivets oradhesives.

[0050]FIG. 4 is a perspective view of a second embodiment of a bat 35utilizing the barrel 11 described in the embodiment of FIGS. 1-3C above.The bat 35 includes a center tube or handle 14 and a transition 12 thatare different from those provided by the integral handle and transition15. The bat 35 also includes the threaded sleeve 21, the barrel 11, thesolid end cap 18, and the knob 16 similar to those described above. Inthis embodiment the transition 12 includes an integral male threadedflange 37 that mates with the threaded sleeve 21 to form the jointbetween handle 14 and barrel 11. This joint allows the barrel 11 to beeasily removed and replaced by the owner. As in the previous embodimentshown in FIGS. 1-3C, the knob 16 and solid end cap 18 are permanentlyattached to the handle 14 and the barrel 11 respectively.

[0051] The handle 14 is preferably a hollow tube made from a metal suchas aluminum or a fiber reinforced composite material such as graphite,fiberglass or aramid fibers in an epoxy, thermoset, or thermoplasticmatrix. The handle 14 could alternatively be solid and formed of theabove stated materials or wood. The thickness of the hollow version ofhandle 14 ranges from about {fraction (1/20)} inch to ¼ inch, dependingupon the type of material and the allowable weight and depending uponthe structural loads to be encountered during play. The outside diameterof the handle 14 ranges from about ¾ inch to about {fraction (9/10)}inch. The length of the handle 14 depends upon the chosen length of thebarrel 11, knob 16, solid end cap 18, and the overall length of the batselected. The transition 12 fitting is attached by welding or adhesivebonding and/or rivets to a distal end of the handle 14 in order tofirmly secure the transition 12 to the handle 14. To the opposite end ofthe handle 14, the knob 16 is mechanically attached via welding or apinned and adhesive joint. Alternatively, the knob 16 can be co-moldedwith the handle 14 if the handle 14 is made from plastics or composites.

[0052]FIG. 5 is a perspective exploded view of the bat shown in FIG. 4.FIG. 5 shows the relative locations of the fitting and threaded flangevarious elements more clearly.

[0053]FIG. 6A is a more detailed exploded perspective view of region 6Aof the bat 35 shown in FIG. 5. In this figure the geometry of thethreaded sleeve 21 and the transition 12 are shown. These drawingsdepict representative configurations for both parts and are not meant tobe restrictive so long as the function of joining the two principlesections of the bat is maintained. Also shown more clearly are thesurfaces which may be bonded or otherwise attached together to join theinside diameter of the barrel 11 and the outside diameter of thethreaded sleeve 21. As can be appreciated, the treaded sleeve 21 isconfigured to receive a larger diameter end of the transition 12.

[0054] The transition 12 is configured to increase the outer diameter ofthe bat from the diameter used to make the handle 14 to the diameter ofthe barrel 11. The length of the transition 12 section is variable,based on a desired weight and appearance. Preferably, the transition 12is fabricated completely or in part from metal such as aluminum so thatintegral threads 38 are provided with good load transfer capability ascan be appreciated from FIG. 6A.

[0055]FIG. 6B is a sectional view of the same region of the bat 35 asshown in FIG. 6A with an alternative threaded sleeve 43 installed in thebarrel 11. The alternative threaded sleeve 43 has a web 45 that spansthe barrel in a radial direction and acts as a tamper resistant seal.The web 45 is preferably a thin film in the range from approximately{fraction (1/100)} to approximately {fraction (3/100)} inch. (That is,in the range from approximately 10 to 30 thousandths of an inch inthickness.) This web or film 43 forms a seal that provides a way ofdetecting whether an interior of the barrel has been accessed forillegal machining or material removal. If, during inspection, the sealis found to be broken, then the bat would be suspect.

[0056] In the transition itself, a hole defining an inner surface 39having a first diameter extending along a central axis 41 of thetransition 12 is sized to closely fit to the handle 14 as shown in FIG.6B. If the handle 14 is made from similar material as the transition 12,e.g., aluminum, the transition 12 can be welded to the handle 14 at aproximal end of the transition 12. If the handle 14 is made fromcomposites, the transition can be bonded with an adhesive and/or pinnedto the handle 14 to form a good structural joint.

[0057] A small step increase in the diameter of the handle 14 and acorresponding step increase in the diameter of the inner surface 39 ofthe transition 12 to a second diameter 47, which is larger than thefirst diameter 39, is incorporated into the bat 35 in order topositively prevent the transition 12 from sliding distally toward thebarrel 11 when the bat is swung. As indicated by a line 49, this step indiameter can be accomplished by a male threaded flange piece 51 that hasan integral sleeve 52 that forms the step and has a diameter thatmatches the second diameter 47. During manufacture, the threaded maleflange piece 51 can be mounted to the handle 14 prior to the remainder53 of the transition 12. To facilitate mounting and adhering the flangepiece 51 to the handle 14, the sleeve 52 is provided with a chamfer 54.This chamfer aids in receiving and spreading an adhesive between thesleeve 52 and the handle 14. The male threaded flange piece 51 actuallyforms part of the transition 12 and is preferably formed of a metal suchas aluminum. The remainder 53 of the transition could be made integralwith the sleeve 52 and formed from metal, but doing so is generally costprohibitive. Thus, the remainder 53 of the transition 12 is preferablyformed of a plastic or composite material having a sleeve of its ownthat surrounds sleeve 52. As such, the remainder 53 of the transition 12can be slid over a proximal end of the handle 14 to surround and abutthe male threaded flange piece 51 during assembly.

[0058]FIG. 7A is a perspective view of the third embodiment of areconfigurable bat 55 with a removable barrel 11 and a knob 16 similarto the barrels and knobs described for the embodiments of FIGS. 1-6Babove. The bat 55 also has structurally different parts including acentral tube 13, a transition 57, a hollow end cap 17, a threaded plug20, and a nut 19. In this embodiment the joint between the transition 57and the barrel 11 is unthreaded. Furthermore, the joint between thebarrel 11 and the hollow end cap 17 is not permanent. The joining of thevarious parts of the bat in this embodiment is accomplished byassembling all of the components onto the central tube 13, including anut 19 which screws onto the threaded plug 20 to secure the assemblytogether.

[0059] The central tube 13 is a structural element made from a metalsuch as aluminum, a fiber reinforced composite materials such asgraphite, fiberglass or aramid fibers in an epoxy, thermoset, orthermoplastic matrix similar to the central tube or handle 14 describedwith regard to the embodiment of FIGS. 4-6B above only longer. In fact,the central tube 13 extends substantially completely through the barrelto the distal end of the bat 55. The length of the central tube 13depends primarily upon the overall length of the bat selected, withsmall adjustments in its length made for the length of the threaded plug20 and the knob 16. The central tube 13 could also be provided as asolid rod of the same or other materials, including wood.

[0060] Approximately midway along the central tube 13, a transition 57is preferably removably attached. Alternatively, the transition 57 canbe attached via welding or adhesive bonding and/or rivets to firmlysecure the transition 57 to the central tube 13. To the proximal end ofthe central tube 13, the knob 16 is mechanically attached as set forthin the description of the other embodiments above. To the distal end ofthe central tube 13 is welded or bonded and/or pinned a threaded plug 20as can be appreciated from the exploded perspective view of FIG. 7B.

[0061]FIG. 7B better shows the various components of the bat in theirrelative assembly positions. Specifically, FIG. 7B shows the threadedplug 20, the nut 19, the hollow end cap 17, and the central location ofthe transition 57. The threaded plug 20 is for clamping the end cap 17onto the end of the barrel 11 to hold the barrel against the transitionin an assembled position.

[0062] As in the previously described embodiments, the transition 57 isconfigured to increase the outer diameter of the bat from that of thecentral tube 13 including a handle portion 59 to the diameter of thebarrel 11. The length of the transition 57 is variable, based on desiredweight and appearance. In this embodiment, the transition 57 may befabricated from metal such as aluminum, an injection molded engineeringthermoplastic, thermoset material, or other material since integralthreads are not required. The hole through the transition 57, along thecentral axis of the transition 57, is sized to closely fit to the centertube 13. Preferably the transition 57 is removably mounted on the centertube 13 so that the transitions 57 of different configurations can beused. However, if the center tube 13 and the transition 57 are both madefrom the same metal, e.g., aluminum, the two can be welded together at aproximal end of the transition 57. If the center tube 13 is made fromcomposites, the two may be bonded together with an adhesive and/orpinned together to form a good structural joint.

[0063] In the embodiments of FIGS. 7A-8B, a smooth flange 61 of thetransition 57 mates with the barrel 11. The smooth flange 61 is notthreaded, but presents a smooth surface which slides into and supportsthe barrel 11 as shown in FIGS. 7B and 7C. The flange 61 itself isslightly recessed radially from an outermost surface 62 of thetransition 57. This recess allows an end of the barrel 11 to squarelymate with a surface 63 of the transition 57 extending radially outwardlyfrom the flange 61 at the joint between the flange 61 and the remainderof the body of the transition 57. The radially extending surface 63 isnormal to a central axis 65 extending along the length of the centraltube 13.

[0064]FIG. 7C is a sectional side view of the bat 55 of FIG. 7A showinghow the barrel 11 and transition 57 fit together. As shown, an innersurface of the barrel 11 can be provided with an annular depression 66and the smooth flange 61 can be provided with a corresponding annularprotrusion 67 for snap-fitting into the depression 66.

[0065] In the embodiments of FIGS. 7A-8B, a small step change in thediameter of the central tube 13 and a corresponding diameter change inthe central hole of the transition 57 may be included in the structureas best shown in the cross sectional view of FIG. 7C. This step changein the outer diameter of the central tube 13 is provided by adding awrap or sleeve 69 to the central tube 13. The wrap or sleeve 69 ispermanently bonded to the central tube 13. The wrap 69 can be adhesivelybonded to the center tube 13. This may be accomplished by a separateadhesive material applied between the wrap and the center tube 13.Alternatively, adhesive bonding may be provided by the nature of thematerial from which the wrap is formed. That is, the wrap may be formedof a fibrous material that is pre-impregnated with a resin which mayalso include additional fibrous materials. Such a wrap can be adhered byapplying a heat treatment to catalyze a reaction between the fibers andthe resinous material. At the same time, the resinous material forms abond with the center tube 13 and bonds the wrap thereto. The wrap orsleeve material is selected based on its compatibility with the materialof the center tube 13 and a relative ease of assembly desired formanufacturing purposes. Preferably, the sleeve 69 is an aluminum sleevethat is adhesively bonded to the center tube 13. As described above, achamfer 70 is provided to aid in receiving and distributing an adhesivebetween the sleeve 69 and the center tube 57. Additionally oralternatively a retention pin 71 can be used to secure the sleeve 69 tothe center tube 57. A step 72 in the inner surface of the transition 57is formed by providing the inner surface with a larger diameter to matchthat of the wrap or sleeve 69. The steps in both of the outer diameterof the central tube 13 and the inner surface of the transition 57 areprovided to positively prevent the transition from sliding in a proximaldirection toward the knob 16 when the nut 19 is tightened onto thethreaded plug 20, for example.

[0066]FIG. 7D is a more detailed view of a region 7D of FIG. 7B showingthe threaded end plug 20 and the distal end of the center tube 13, whichare permanently connected during assembly as described above. In thisfigure the geometry of the threaded plug 20 and the central tube 13 areshown. Also shown more clearly are the surfaces which may be bonded orotherwise attached together to join the inside diameter of the centraltube 13 and the smooth outside diameter of the threaded plug 20. Thisjoint provides a structurally stable connection that is able towithstand the tensile forces that are present in the center tube 13 andend plug 20 during the clamping of the barrel 11 on the bat 55 that isregularly present after assembly of the barrel 11 on the bat 55.

[0067]FIG. 7E is a detailed view of a region 7E showing the hollow endcap 17 and the nut 19. In this figure the geometry of the hollow end cap17 and the nut 19 are shown. Also shown more clearly is the interfacebetween the inside diameter of the barrel 11 and the smooth flange onthe hollow end cap 17. The hollow end cap 17, as shown in thisembodiment of the invention, incorporates a smooth hole 73 which passesfully through the end cap 17 along the center axis 65 of the bat 55.This allows the threaded plug 20 to pass through and for the nut 19 tobe attached to the threaded plug 20 to tighten the assembly together. Inanother embodiment of the hollow end cap 17, the center hole is threadedso that a separate nut 19 is not required. The hollow end cap 17 itselfincludes a dome shaped end, a counterbore 75 to the central hole 73 (ifa nut 19 is used), and a smooth flange 77 that slides into and supportsthe barrel 11. Like on the transition 57 described above, this flange isslightly recessed to allow the end of the barrel 11 to squarely matewith a surface extending radially from a center of the end cap 17 andbeing normal to the axis 65 extending down the length of the centraltube 13.

[0068]FIG. 7F is a sectional side view of an alternative embodiment of athreaded end plug 78, end cap 79, and nut 80. In this embodiment, thethreaded portion is provided by a threaded shaft 82 that is inserted ina main body of the plug 78 and extends distally to receive the nut 80.Since the shaft 82 is smaller in diameter than the threaded portion ofthe threaded end plug 20, the hole through the end cap 79 can besmaller. Furthermore, because the shaft 82 is smaller in diameter thanthe threaded portion of plug 20, the shaft 82 may be made of a strongerand denser material such as stainless steel without a significant weightimpact. Otherwise, the end cap 79, plug 78, and nut 80 assembly issubstantially similar to that shown and described with regard to FIGS.7A-7E above.

[0069]FIG. 8A is an exploded perspective view of a further embodiment ofa bat 85 in accordance with the invention similar to the embodiments ofFIGS. 7A-7F. However, instead of a threaded end plug 20, 79 and nut 19,80 to hold the end cap in place, the end plug 20, 79 has been replacedby an end plug 86 having internal threads and the assembly nut 19, 80has been replaced by a screw 88. The embodiment of FIG. 8A is otherwisesubstantially similar to that of FIGS. 7A-7F.

[0070]FIG. 8B is a sectional side view of a portion of the bat 85. Theportion of the bat 85 shown in FIG. 8B differs from the embodiments ofFIGS. 7A-7F. As shown, the end plug 86 receives the threaded screw 88.The head of the screw 88 holds a modified end cap 90 in place on the endof the center tube 13 and the barrel 11.

[0071] It should be noted that each of threaded sleeves or fittings 21,22, nut 19, 80 or analogous screw 88, threaded end plugs 20, 79,internally threaded end plug 86, end caps 17, 78, 90 and transitionpieces 12 and 59 are all couplers. Additional couplers may also besubstituted for these elements without departing from the spirit andscope of the invention. However, the configuration of the couplers isconsidered to be unique and very advantageous.

[0072] In all of the embodiments, the couplers are located andconfigured to spread bending forces over large sections and along greatlengths of the bats 5, 35, 55, and 85. In the embodiment of FIGS. 1-6B,this is accomplished by providing the couplings 20, 21, and 51 withbearing surfaces comprising female threads 27 and male threads 31 and 38as shown in FIGS. 3B, 3C, and 6A. As can be appreciated, the bearingsurfaces are at radii that are almost as great as the diameter of thebarrel. As such, the sections over which the bending forces are spreadduring play are much greater than they would be if the bearing surfaceswere at smaller radii. Furthermore, the strength of the materialdistributed at the larger radii is much greater. Still further, thebearing surfaces of the mating couplings 20, 21, and 51 extend asufficient length in the axial directions to distribute the bendingloads along a substantial length of the bats 5 and 35.

[0073] In the embodiments of FIGS. 7A-8B the bearing surfaces arerelatively smooth surfaces comprising portions of smooth flange 61 andsurfaces 63 on transitions 57, and analogous surfaces on each of the endcaps 17, 77, and 90. These bearing surfaces abut bearing surfaces of thebarrel 11 and apply clamping or compressive forces under the action ofthe center tube 13, end plugs 20, 79, 86, and the nuts 19, 80 or screw88. The nuts 19, 80 or screws exert the tensile force when turned in atightening direction. The nuts 19, 80 can have a hex or otherconfiguration. The screw can incorporate a hex or other shapeddepression in the head for conventional or other manipulation. The nuts,19, 80 and screw 88 may be configured with a security or customconfiguration that requires a special tool for tightening or loosening.

[0074] The center tube 13, end plugs 20, 79, 86, and nuts 19, 80 orscrew 88 all exert tensile forces at much smaller radii than the barrel11 and its bearing surfaces. These tensile forces act to hold thevarious components of the bats 55, 85 together in a clampedconfiguration. Significant bending forces are kept from affecting thesecomponents of smaller radii because of the strength of the barrel 11,end caps 17, 77, 90, and transition 57 and their geometries that spreadthe forces along the length of the center tube 13 during impact.Specifically, a force of impact applied generally radially on the barrelis transferred at least in part to the end caps 17, 77, 90 andtransition which in turn transfer at least a portion of the force to thecenter tube 13. However, the force of impact that is transferred to thecenter tube 13 is transferred along an inner surface of the through holeof the end caps 17, 77, 90 and along the inner surface of the transition57. This transfers bending forces that are not taken up by the barrel 11and other components along a large area of the center tube and enablesthese bending forces to be taken up along substantially an entire lengthof the center tube. Thus stress concentrations are avoided and thetendency to failure due to these forces is reduced. Furthermore, the batmay be made more aesthetic by providing the Transition pieces withsmooth outer surfaces as opposed to the ribbed surfaces shown in theFigures.

[0075] Still further, it is contemplated that alternative end plugs andcaps could be substituted for greater security and safety against apiece such as a barrel from flying off a distal end of the bat duringplay. Such alternative plugs could have a disk shaped head integral witha shaft that is fixed in a distal end of a center tube similar to theembodiments described above. Such an integral disk structure wouldsecure the end cap and barrel against distal movement. In this case theend cap and barrel would have to be installed from a proximal end of thecenter tube. Furthermore, the transition and barrel would have to besecured against movement in a proximal direction such as by threadsbetween the transition piece and the center tube.

[0076] Another secure system of securing the barrel against distalmovement may include redundancy of locking mechanisms. For example, anend piece can be provided with an oblong opening for receiving an oblonghead portion on an extension of an end plug. Thus, the head portion canbe inserted through the oblong opening and turned ninety degrees. Inthis orientation, movement of the end cap in a distal direction isblocked since axes of the oblong opening and head portion areperpendicular to each other. To secure the end cap and the end plug inthis orientation, an anti-rotation wedging mechanism is inserted onopposite sides of the oblong head portion and tightened with a pairscrews.

[0077] One of the advantages of the present invention that isaccomplished by all of the embodiments, to some degree, is that the bats5, 35, 55, and 85 all incorporate components that are more easilymanufactured than are the components of the bats of the past. Thus, thebats 5, 35, 55, and 85 can be made less expensively. Specifically, thisis accomplished by forming one or more of the components having complexshapes that are difficult to machine from a plurality of components ofshapes that are easily machined or easily molded. For example, thebarrel 11 for all of the embodiments is a simple tubular component asopposed to the barrels of the past that transition into complextransition and butt end portions that require special machining.Similarly, the molded transitions 12, 57, and end caps 18, 17, 77, 79,and 90 are much more easily molded than machined as required in thepast. Forming couplings 20, 21, and 51 by molding is also an easymanufacturing step, and adhesively bonding the couplings to theirrespective barrel and transition pieces is a further simplemanufacturing step. The resulting advantage of providing a bat that caneasily be dismantled and reconfigured is worth the additionalmanufacturing steps. Especially, since the components over all can bemade for less than the components of bats of the past. Still further,the performance of the bats 5, 35, 55, and 85 is adjustable as set forthabove.

[0078] Another aspect of the performance of the bats of the presentinvention is that the materials and configurations lend to a lightweight bat. With most of the components formed of light weightcomposites as set forth above, the weight of the bats can easily be keptunder 30 ounces. In fact, for most lengths of bats, it is possible tokeep the weights in a range from 22 ounces to 30 ounces whenincorporating the composite materials with an epoxy, thermoset, orthermoplastic matrix as set forth above. In particular, a polyurethanethermoset matrix material is beneficial in providing a strong lightweight bond. Weight can be kept low by forming most or all of the largercomponents of the lighter weight composite components, while the smallercomponents such as end plugs and other couplers may be formed of densermaterials such as aluminum or other materials.

[0079] As can be appreciated, a grip (not shown) will normally beprovided on bats of all of the above described embodiments. Typically,this grip may be of any of a variety of relatively thin conventionalmaterials and extend from the knob 16 distally a distance in the rangefrom 10 inches to 15 inches.

[0080] The embodiments and examples set forth herein were presented inorder to best explain the present invention and its practicalapplication and to thereby enable those of ordinary skill in the art tomake and use the invention. However, those of ordinary skill in the artwill recognize that the foregoing description and examples have beenpresented for the purposes of illustration and example only. Thedescription as set forth is not intended to be exhaustive or to limitthe invention to the precise form disclosed. Many modifications andvariations are possible in light of the teachings above withoutdeparting from the spirit and scope of the forthcoming claims. Forexample, it is contemplated that many couplers and configurations ofcouplers could be provides in accordance with the above describedprinciples without departing from the spirit and scope of the presentinvention.

1. A reconfigurable ball bat comprising: a center tube having a firstdiameter and a first length extending between a proximal end and adistal end of the center tube; a transition piece mounted on the centertube at a position spaced from the proximal end of the center tube, thetransition piece having a bearing surface with a minimum diameter in arange from 2 to 3½ times the first diameter; a cylindrical barrel havinga proximal end with a proximal bearing surface having a minimum diameterin the range from 2 to 3½ times the first diameter, the proximal bearingsurface of the barrel solely in contact with the bearing surface of thetransition piece.
 2. The reconfigurable ball bat of claim 1, furthercomprising a knob connected to the proximal end of the center tube. 3.The reconfigurable ball bat of claim 1, further comprising an end capconnected to the distal end of the barrel.
 4. The reconfigurable ballbat of claim 3, further comprising the center tube connected to the endcap.
 5. The reconfigurable ball bat of claim 4, further comprising: anend plug connected to a distal end of the center tube; an end capabutting a distal end of the barrel; and an assembly screw engaging theend plug and supporting the end cap on the distal end of the barrel. 6.The reconfigurable ball bat of claim 1, wherein a portion of the centertube is concentric with and disposed within the barrel.
 7. Areconfigurable ball bat comprising: a center tube having a firstdiameter and a first length extending between a proximal end and adistal end of the center tube; a transition piece mounted on the centertube at a position spaced from the proximal end of the center tube, thetransition piece having a bearing surface; a barrel having a proximalend with a proximal bearing surface, the proximal bearing surface of thebarrel solely in contact with the bearing surface of the transitionpiece; and a coupler at a distal end of the barrel, said couplerremovably mounting the barrel on the transition piece, and said couplerbeing the only mechanism that positively inhibits axial movement of thebarrel away from the transition piece.
 8. A reconfigurable ball batcomprising: a center tube having a first diameter and a first lengthextending between a proximal end and a distal end of the center tube; atransition piece mounted on the center tube at a position spaced fromthe proximal end of the center tube the transition piece having abearing surface with a minimum diameter in a range from 2 to 3½ timesthe first diameter; a barrel having a proximal end with a proximalbearing surface having a minimum diameter in the range from 2 to 3½times the first diameter the proximal bearing surface of the barrelsolely in contact with the bearing surface of the transition piece; anda coupler at a distal end of the barrel said coupler removably mountingthe barrel on the transition piece; wherein: the coupler is one of aplurality of couplers; the minimum diameter is one of a plurality ofrespective minimum diameters of said plurality of couplers; and theminimum diameter of each of the couplers is in a range from 2 to 3½times the first diameter.
 9. The reconfigurable ball bat of claim 1,wherein the center tube comprises a handle portion of the bat.
 10. Areconfigurable ball bat comprising: a center tube having a firstdiameter and a first length extending between a proximal end and adistal end of the center tube; a transition piece mounted on the centertube at a position spaced from the proximal end of the center tube, thetransition piece having a bearing surface; a barrel having a proximalend with a proximal bearing surface the proximal bearing surface of thebarrel solely in contact with the bearing surface of the transitionpiece; wherein: the barrel is removably mounted to the transition pieceby a coupler that can be manipulated by hand or with a tool; and thecoupler is separate from structure which mounts the transition piece onthe center tube; whereby the barrel can be removed and replaced quicklyand easily.
 11. A method of making a ball bat, comprising the steps of:forming a center tube to have a first inner diameter and a first outerdiameter; forming a transition piece having an outer surface including abarrel abutting bearing surface and an opening having an inner surfaceof a dimension for matingly receiving the first outer diameter of thecenter tube; forming a barrel having a second outer diameter and asecond inner diameter, the second inner diameter matching the barrelabutting bearing surface on the outer surface of the transition piece;connecting the transition piece to the center tube; and assembling theball bat by removably connecting the barrel to the barrel abuttingbearing surface of the transition piece in a separate step from the stepof connecting the transition piece to the center tube.
 12. The method ofmaking a ball bat of claim 11, further comprising: providing a knob forthe ball bat; providing an end cap for the ball bat wherein the step ofassembling the ball bat further comprises: connecting the knob to aproximal end of the center tube; and connecting the end cap to a distalend of the barrel.
 13. The method of making a ball bat in accordancewith claim 12, further comprising: forming an end plug; providing anassembly screw; connecting the end cap to the barrel by: connecting theend plug to the center tube; and engaging the screw in the end plug. 14.The method of making a ball bat in accordance with claim 13, wherein thestep of connecting the barrel to the transition piece comprises:abutting a proximal end of the barrel with the barrel abutting bearingsurface of the transition piece; abutting the end cap with the distalend of the barrel; and clamping the barrel between the transition pieceand the end cap by: engaging the assembly screw in the end plug; andturning the assembly screw.
 15. The method of making a ball bat inaccordance with claim 12, further comprising forming the transitionpiece, the knob, and the end cap of a thermoplastic or thermosetmaterial.
 16. A reconfigurable ball bat kit comprising: a center tube;at least one transition piece, a plurality of barrels selectivelyconnectable and separable from the center tube; wherein the plurality ofbarrels are selectively supported on the center tube by the transitionpiece; and wherein the plurality of barrels have a variety of diameters.17. Canceled
 18. The kit of claim 16, further comprising means forselectively and removably mounting and supporting the barrels on thecenter tube by the transition piece.
 19. The kit of claim 16, wherein:the at least one transition piece is one of a plurality of transitionpieces having barrel bearing surfaces of a corresponding variety ofdiameters for supporting the plurality of barrels; and the kit furthercomprising: at least one knob; and at least one end cap.
 20. The kit ofclaim 19, further comprising: an end plug for connecting to the centertube; and an assembly screw for clamping the barrel between thetransition piece and the end cap.
 21. The kit of claim 16, furthercomprising: a tamper resistant element for connection to the barrel;wherein the tamper resistant element inhibits tampering with an interiorof the barrel without obvious modification to the tamper resistantelement.
 22. The kit of claim 16, further comprising structure on one ormore of the center tube, transition piece, and the barrel enablingsimple manipulation so that the kit can be assembled and disassembledquickly and easily in the field.
 23. A method of using a reconfigurableball bat, wherein the ball bat includes a center tube, at least onetransition piece having an outer diameter increasing from a firstdiameter of the center tube to a second diameter, and a plurality ofbarrels, the method comprising: selecting a barrel from among thebarrels; and forming a tapered transition from the center tube to thebarrel by supporting the barrel on the transition piece generally at thesecond diameter.
 24. A reconfigurable ball bat comprising: a center tubehaving a first diameter and a first length extending between a proximalend and a distal end of the center tube; a transition piece mounted onthe center tube at a position spaced from the proximal end of the centertube; a barrel having a second diameter greater than the first diameter,the barrel having a proximal end in contact with the transition piece;and a coupler at a distal end of the barrel, said coupler removablymounting the barrel on the transition piece.
 25. A reconfigurable ballbat in a range of standard sizes comprising: a center tube including ahandle portion; a barrel section removably connected to the handleportion and receiving the center tube therethrough; a butt end supportedon the barrel; a knob supported on the handle portion; wherein: thehandle portion, barrel section, butt end, and knob form a bat of lengthwithin the range of standard sizes; and the reconfigurable ball batweighs less than or equal to 30 ounces.
 26. The reconfigurable ball batof claim 25 wherein the bat weighs less than or equal to 28 ounces. 27.The reconfigurable ball bat of claim 25, wherein the bat weighs lessthan or equal to 26 ounces.
 28. The reconfigurable ball bat of claim 25,wherein the bat has a weight in a range from 22 ounces to 24 ounces. 29.The reconfigurable ball bat of claim 25, wherein the bat has a weight inounces equal to a length in inches minus at least three.
 30. Thereconfigurable ball bat of claim 25, wherein the bat has a transitionforming a relatively smooth continuous surface including at leastportions of the barrel section and the handle portion.
 31. Thereconfigurable ball bat of claim 25, wherein at least one of the handleportion, barrel section, and butt end is removably connected to the restof the bat so that the bat can be easily and quickly taken apart forinspection and put back together on the field.
 32. A reconfigurable ballbat kit comprising: a center tube; at least one transition piece, atleast one barrel wherein the barrel is selectively connectable andseparable from the center tube; and a tamper resistant element connectedto and enclosing an interior of the barrel; wherein the tamper resistantelement inhibits access to an interior of the barrel without obviousmodification to the tamper resistant element.